Adapter assembly for interconnecting electromechanical surgical devices and surgical loading units, and surgical systems thereof

ABSTRACT

The present disclosure relates to adapter assemblies for use with and to electrically and mechanically interconnect electromechanical surgical devices and surgical loading units, and to surgical systems including hand held electromechanical surgical devices and adapter assemblies for connecting surgical loading units to the hand held electromechanical surgical devices.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/708,520, filed Sep. 19, 2017, which is a continuation of U.S.application Ser. No. 14/700,917, filed Apr. 30, 2015, now U.S. Pat. No.9,763,661, which claims the benefit of and priority to U.S. ProvisionalPatent Application Ser. No. 62/017,510, filed Jun. 26, 2014, the entiredisclosure of which is incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to adapter assemblies for use in surgicalsystems. More specifically, the present disclosure relates to adapterassemblies for use with and to electrically and mechanicallyinterconnect electromechanical surgical devices and surgical loadingunits, and to surgical systems including hand held electromechanicalsurgical devices and adapter assemblies for connecting surgical loadingunits to the hand held electromechanical surgical devices.

2. Background of Related Art

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating and/or manipulatingelectromechanical surgical devices. In many instances theelectromechanical surgical devices include a handle assembly, which isreusable, and disposable loading units and/or single use loading unitsor the like that are selectively connected to the handle assembly priorto use and then disconnected from the handle assembly following use inorder to be disposed of or in some instances sterilized for re-use.

In certain instances, an adapter assembly is used to interconnect anelectromechanical surgical device with any one of a number of surgicalloading units to establish a mechanical and/or electrical connectiontherebetween. Due to the complexity of the adapter assembly and theelectromechanical surgical device, it is important to ensure that allelectrical and mechanical connections therebetween can be easily,reliably and repeatedly accomplished.

Accordingly, a need exists for an adapter assembly that provides arobust way of electromechanically interconnecting with the surgicaldevice.

SUMMARY

The present disclosure relates to adapter assemblies for use with and toelectrically and mechanically interconnect electromechanical surgicaldevices and surgical loading units, and to surgical systems includinghand held electromechanical surgical devices and adapter assemblies forconnecting surgical loading units to the hand held electromechanicalsurgical devices.

According to an aspect of the present disclosure, an adapter assemblyfor selectively interconnecting a surgical loading unit that isconfigured to perform a function and a surgical device that isconfigured to actuate the loading unit, is provided. The loading unitmay include at least one axially translatable drive member, and thesurgical device may include at least one rotatable drive shaft. Theadapter assembly includes a housing configured and adapted forconnection with the surgical device and to be in operative communicationwith each rotatable drive shaft of the surgical device; an outer tubehaving a proximal end supported by the housing and a distal endconfigured and adapted for connection with the loading unit, wherein thedistal end of the outer tube is in operative communication with each ofthe axially translatable drive member of the loading unit; theforce/rotation transmitting/converting assembly for interconnecting arespective one drive shaft of the surgical device and a respective oneaxially translatable drive member of the loading unit; and an electricalassembly supported within at least one of the housing and the outertube. The electrical assembly includes a circuit board and an electricalconnector. The electrical connector includes a connector housing coupledto a plurality of electrical contact pins. The plurality of electricalcontact pins are electrically connected to the circuit board and areconfigured and adapted to selectively electrically connect to acomplementary electrical plug of the surgical device. Each of theelectrical contact pins of the plurality of electrical contact pinsextends through the connector housing.

The electrical assembly may a single connector housing, where each ofthe electrical contact pins of the plurality of electrical contact pinsextends through the single connector housing. Each of the electricalcontact pins of the plurality of electrical contact pins may be fixedfrom moving relative to the single connector housing.

In disclosed embodiments, the connector housing is secured to theplurality of electrical contact pins via over-molding. Each of theelectrical contact pins of the plurality of electrical contact pins mayinclude a hole extending therethrough, such that a portion of theconnector housing extends through the hole of each of the electricalcontact pins of the plurality of electrical contact pins.

A proximal portion of each of the electrical contact pins of theplurality of electrical contact pins may include a rectangularcross-section.

The connector housing may include at least one projection extending froma surface thereof. A distal face of the at least one projection isconfigured to abut the circuit board when the plurality of electricalcontact pins are electrically connected to the circuit board. A proximalface of the at least one projection is configured to abut a surface ofproximal cap to prevent unintended disengagement between the electricalconnector and the circuit board.

In disclosed embodiments, the electrical assembly includes a straingauge supported on and electrically connected to the circuit board. Arotatable drive shaft of the surgical device extends through the straingauge. The electrical assembly may also include a slip ring disposedabout a portion of a first force/rotation transmitting/convertingassembly. The slip ring is in electrical connection with the circuitboard, and includes an electrical contact supported therein formaintaining electrical contact with at least one electrical componentwithin the adapter assembly.

The present disclosure also relates to an electrical assembly for usewith an adapter assembly for selectively interconnecting a surgicalloading unit that is configured to perform a function and a surgicaldevice that is configured to actuate the loading unit. The electricalassembly includes a circuit board and an electrical connector. Theelectrical connector includes a connector housing coupled to a pluralityof electrical contact pins. The plurality of electrical contact pins areelectrically connectable to the circuit board and are configured andadapted to selectively electrically connect to a complementaryelectrical plug of a surgical device. Each of the electrical contactpins of the plurality of electrical contact pins extends through theconnector housing.

In disclosed embodiments, the electrical assembly includes a singleconnector housing, such that each of the electrical contact pins of theplurality of electrical contact pins extends through the singleconnector housing. Here, each of the electrical contact pins of theplurality of electrical contact pins is fixed from moving relative tothe single connector housing.

It is also disclosed that the connector housing is secured to theplurality of electrical contact pins via over-molding. Also, each of theelectrical contact pins of the plurality of electrical contact pins mayinclude a hole extending therethrough, such that a portion of theconnector housing extends through the hole of each of the electricalcontact pins of the plurality of electrical contact pins.

A proximal portion of each of the electrical contact pins of theplurality of electrical contact pins may include a rectangularcross-section.

In disclosed embodiments, the connector housing includes at least oneprojection extending from a surface thereof. A distal face of the atleast one projection is configured to abut the circuit board when theplurality of electrical contact pins are electrically connected to thecircuit board. A proximal face of the at least one projection isconfigured to abut a surface of proximal cap 210 to prevent unintendeddisengagement between the electrical connector and the circuit board.

It is further disclosed that the electrical assembly further comprises astrain gauge supported on and electrically connected to the circuitboard. Additionally, the electrical assembly may also include a slipring disposed in electrical connection with the circuit board, such thatthe slip ring includes an electrical contact supported therein formaintaining electrical contact with at least one electrical componentwithin the adapter assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of an adapter assembly, in accordance withan embodiment of the present disclosure, interconnected between anexemplary electromechanical surgical device and an end effectorassembly;

FIG. 1B is a perspective view illustrating an attachment of a proximalend of the adapter assembly to a distal end of the electromechanicalsurgical device;

FIG. 2A is a front, perspective view of the adapter assembly of thepresent disclosure;

FIG. 2B is a rear, perspective view of the adapter assembly of FIG. 2A;

FIG. 3 is a top plan view of the adapter assembly of FIGS. 2A and 2B;

FIG. 4 is a side, elevational view of the adapter assembly of FIGS. 2Aand 2B;

FIG. 5 is a rear, perspective view of the adapter assembly of FIGS. 2Aand 2B, with some parts thereof separated;

FIG. 6 is a rear, perspective view of the adapter assembly of FIGS. 2Aand 2B, with most parts thereof separated;

FIG. 7 is a perspective view of an articulation assembly of the adapterassembly of FIGS. 2A and 2B;

FIG. 8 is an enlarged, perspective view, with parts separated, of thearticulation assembly of FIG. 7;

FIG. 9 is a perspective view of the articulation assembly of FIG. 7,shown in a first orientation;

FIG. 10 is a perspective view of the articulation assembly of FIG. 7,shown in a second orientation;

FIG. 11 is a cross-sectional view as taken along section line 11-11 ofFIG. 9;

FIG. 12A is a perspective view of an electrical assembly of the adapterassembly of FIGS. 2A and 2B;

FIG. 12B is a perspective view of the electrical assembly of FIG. 12Ashowing a connector housing separated from a circuit board;

FIG. 12C is a perspective view of the connector housing of FIG. 12B;

FIG. 12D is a perspective view of an electrical contact pin of theconnector housing of FIGS. 12B-12C;

FIG. 13 is a perspective view of the electrical assembly of FIG. 12Ashown connected to the core housing of the adapter assembly of FIGS. 2Aand 2B;

FIG. 14 is a cross-sectional view as taken along section line 14-14 ofFIG. 13;

FIG. 15 is a perspective view of a slip ring cannula or sleeve of theadapter assembly of FIGS. 2A and 2B;

FIG. 16 is an enlarged view of the indicated area of detail of FIG. 2B,illustrating an inner housing assembly of the adapter assembly of FIGS.2A and 2B;

FIG. 17 is a rear, perspective view of the inner housing assembly ofFIG. 16 with an outer knob housing half-section and a proximal capremoved therefrom;

FIG. 18 is a rear, perspective view of the inner housing assembly ofFIG. 16 with the outer knob housing, the proximal cap and a bushingplate removed therefrom;

FIG. 19 is a rear, perspective view of the inner housing assembly ofFIG. 16 with the outer knob housing, the proximal cap, the bushing plateand an inner housing removed therefrom;

FIG. 20 is a rear, perspective view of the an alternative embodiment ofinner housing assembly similar to that shown in FIG. 16 with the outerknob housing and the proximal inner housing removed therefrom;

FIG. 21 is a rear, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 22 is a front, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 23 is a front, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing and the proximal inner housingremoved therefrom;

FIG. 24 is a cross-sectional view as taken along section line 24-24 ofFIG. 2B;

FIG. 25 is an enlarged view of the indicated area of detail of FIG. 24;

FIG. 26 is an enlarged view of the indicated area of detail of FIG. 24,illustrating a lock button being actuated in a proximal direction;

FIG. 27 is a cross-sectional view as taken along section line 27-27 ofFIG. 2B;

FIG. 28 is a cross-sectional view as taken along section line 27-27 ofFIG. 2B, illustrating actuation of the articulation assembly in a distaldirection;

FIG. 29 is a cross-sectional view as taken along section line 29-29 ofFIG. 28;

FIG. 30 is a cross-sectional view as taken along section line 30-30 ofFIG. 28;

FIG. 31 is a cross-sectional view as taken along section line 31-31 ofFIG. 28;

FIG. 32 is a rear, perspective view of a proximal inner housing hubaccording to the present disclosure;

FIG. 33 is a front, perspective view of the proximal inner housing hubof FIG. 32;

FIG. 34 is a front, perspective view of the proximal inner housing hubof FIGS. 32 and 33 illustrating a first and a second force/rotationtransmitting/converting assembly and a reinforcing assembly associatedtherewith;

FIG. 35 is a front, perspective view of a plate bushing of the proximalinner housing assembly of the present disclosure;

FIG. 36 is a rear, perspective view of the plate bushing of FIG. 35;

FIG. 37 is a rear, perspective view of the proximal inner housingassembly illustrating the plate bushing of FIGS. 35 and 36 attachedthereto;

FIG. 38 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom;

FIG. 39 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom and theplate bushing shown in phantom;

FIG. 40 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom;

FIG. 41 is a rear, perspective of the inner housing assembly of FIG. 37illustrating a support plate, according to another embodiment of thepresent disclosure, coupled thereto;

FIG. 42 is a rear, perspective of the inner housing assembly of FIG. 41with the support plate removed therefrom;

FIG. 43 is a front, perspective view of an inner housing assemblyaccording to another embodiment of the present disclosure with the outerknob housing, the proximal inner housing removed therefrom;

FIG. 44 is a rear, perspective view of the inner housing assembly ofFIG. 43 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 45 is a perspective view of a bracket assembly of the inner housingassembly of FIGS. 43 and 44;

FIG. 46 is a perspective view of a reinforcing sleeve for use with theinner housing assembly of FIGS. 43 and 44;

FIG. 47 is a perspective view of the inner housing assembly of FIGS. 43and 44, illustrating the reinforcing sleeve of FIG. 46 supportedthereon; and

FIG. 48 is a perspective view, with parts separated, of an exemplaryloading unit for use with the surgical device and the adapter of thepresent disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical devices, adapterassemblies, and loading unit detection assemblies for surgical devicesand/or handle assemblies are described in detail with reference to thedrawings, in which like reference numerals designate identical orcorresponding elements in each of the several views. As used herein theterm “distal” refers to that portion of the adapter assembly or surgicaldevice, or component thereof, farther from the user, while the term“proximal” refers to that portion of the adapter assembly or surgicaldevice, or component thereof, closer to the user.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand held electromechanical instrument configured for selectiveattachment thereto of a plurality of different end effectors that areeach configured for actuation and manipulation by the powered hand heldelectromechanical surgical instrument.

As illustrated in FIG. 1A, surgical device 100 is configured forselective connection with an adapter assembly 200, and, in turn, adapterassembly 200 is configured for selective connection with a loading unit300 (e.g., an end effector, or multiple- or single-use loading unit; seeFIG. 48). Surgical device 100 and adapter assembly 200, together, maycomprise an electromechanical surgical system that is configured andadapted to selectively connect with a loading unit 300 and to actuateloading unit 300.

As illustrated in FIGS. 1A and 1B, surgical device 100 includes a handlehousing 102 including a circuit board (not shown), and a drive mechanism(not shown) is situated therein. The circuit board is configured tocontrol the various operations of surgical device 100. Handle housing102 defines a cavity therein (not shown) for selective removable receiptof a rechargeable battery (not shown) therein. The battery is configuredto supply power to any of the electrical components of surgical device100.

Handle housing 102 includes an upper housing portion 102 a which housesvarious components of surgical device 100, and a lower hand grip portion102 b extending from upper housing portion 102 a. Lower hand gripportion 102 b may be disposed distally of a proximal-most end of upperhousing portion 102 a. The location of lower housing portion 102 brelative to upper housing portion 102 a is selected to balance a weightof a surgical device 100 that it is connected to or supporting adapterassembly 200 and/or end effector 300.

Handle housing 102 provides a housing in which the drive mechanism issituated. The drive mechanism is configured to drive shafts and/or gearcomponents in order to perform the various operations of surgical device100. In particular, the drive mechanism is configured to drive shaftsand/or gear components in order to selectively move a tool assembly 304of loading unit 300 (see FIGS. 1A and 48) relative to a proximal bodyportion 302 of loading unit 300, to rotate loading unit 300 about alongitudinal axis “X” (see FIG. 1A) relative to handle housing 102, tomove/approximate an anvil assembly 306 and/or a cartridge assembly 308of loading unit 300 relative to one another, and/or to fire a staplingand cutting cartridge within cartridge assembly 308 of loading unit 300.

As illustrated in FIG. 1B, handle housing 102 defines a connectingportion 108 configured to accept a corresponding drive coupling assembly210 of adapter assembly 200. Specifically, connecting portion 108 ofsurgical device 100 has a recess 108 a that receives a proximal cap 210a (FIGS. 5 and 6) of drive coupling assembly 210 of adapter assembly 200when adapter assembly 200 is mated to surgical device 100. Connectingportion 108 houses three rotatable drive connectors 118, 120, 122 whichare arranged in a common plane or line with one another.

When adapter assembly 200 is mated to surgical device 100, each ofrotatable drive connectors 118, 120, 122 of surgical device 100 coupleswith a corresponding rotatable connector sleeve 218, 220, 222 of adapterassembly 200 (see FIG. 1B). In this regard, the interface betweencorresponding first drive connector 118 and first connector sleeve 218,the interface between corresponding second drive connector 120 andsecond connector sleeve 220, and the interface between correspondingthird drive connector 122 and third connector sleeve 222 are keyed suchthat rotation of each of drive connectors 118, 120, 122 of surgicaldevice 100 causes a corresponding rotation of the correspondingconnector sleeve 218, 220, 222 of adapter assembly 200.

The mating of drive connectors 118, 120, 122 of surgical device 100 withconnector sleeves 218, 220, 222 of adapter assembly 200 allowsrotational forces to be independently transmitted via each of the threerespective connector interfaces. The drive connectors 118, 120, 122 ofsurgical device 100 are configured to be independently rotated by thedrive mechanism of surgical device 100. In this regard, a functionselection module (not shown) of the drive mechanism selects which driveconnector or connectors 118, 120, 122 of surgical device 100 is to bedriven by the motor of surgical device 100.

Since each of drive connectors 118, 120, 122 of surgical device 100 hasa keyed and/or substantially non-rotatable interface with respectiveconnector sleeves 218, 220, 222 of adapter assembly 200, when adapterassembly 200 is coupled to surgical device 100, rotational force(s) areselectively transferred from drive connectors of surgical device 100 toadapter assembly 200.

The selective rotation of drive connector(s) 118, 120 and/or 122 ofsurgical device 100 allows surgical device 100 to selectively actuatedifferent functions of loading unit 300. For example, selective andindependent rotation of first drive connector 118 of surgical device 100corresponds to the selective and independent opening and closing of toolassembly 304 of loading unit 300, and driving of a stapling/cuttingcomponent of tool assembly 304 of loading unit 300. As an additionalexample, the selective and independent rotation of second driveconnector 120 of surgical device 100 corresponds to the selective andindependent articulation of tool assembly 304 of loading unit 300transverse to longitudinal axis “X” (see FIG. 1A). Additionally, forinstance, the selective and independent rotation of third driveconnector 122 of surgical device 100 corresponds to the selective andindependent rotation of loading unit 300 about longitudinal axis “X”(see FIG. 1A) relative to handle housing 102 of surgical device 100.

As illustrated in FIG. 1A, handle housing 102 supports a plurality offinger-actuated control buttons, rocker devices and the like foractivating various functions of surgical device 100.

Reference may be made to International Application No.PCT/US2008/077249, filed Sep. 22, 2008 (Inter. Pub. No. WO 2009/039506)and U.S. patent application Ser. No. 12/622,827, filed on Nov. 20, 2009(U.S. Pat. Pub. No. US 2011-0121049), the entire content of each ofwhich being incorporated herein by reference, for a detailed descriptionof various internal components of and operation of exemplaryelectromechanical, hand-held, powered surgical instrument 100.

With particular reference to FIGS. 1B-2B, adapter assembly 200 includesan outer knob housing 202 and an outer tube 206 extending from a distalend of knob housing 202. Knob housing 202 and outer tube 206 areconfigured and dimensioned to house the components of adapter assembly200. Outer tube 206 is dimensioned for endoscopic insertion, inparticular, outer tube 206 is passable through a typical trocar port,cannula or the like. Knob housing 202 is dimensioned to not enter thetrocar port, cannula of the like. Knob housing 202 is configured andadapted to connect to connecting portion 108 of handle housing 102 ofsurgical device 100.

Adapter assembly 200 is configured to convert a rotation of either ofdrive connectors 118, 120 and 122 of surgical device 100 into axialtranslation useful for operating a drive assembly 360 and anarticulation link 366 of loading unit 300, as illustrated in FIG. 48 andas will be described in greater detail below. As illustrated in FIGS. 5,6, 13, 14, 17, 18, 20, 25-34 and 37-40, adapter assembly 200 includes aproximal inner housing assembly 204 rotatably supporting a firstrotatable proximal drive shaft 212, a second rotatable proximal driveshaft 214, and a third rotatable proximal drive shaft 216 therein. Eachproximal drive shaft 212, 214, 216 functions as a rotation receivingmember to receive rotational forces from respective drive shafts ofsurgical device 100, as described in greater detail below.

As described briefly above, inner housing assembly 210 of shaft assembly200 is also configured to rotatably support first, second and thirdconnector sleeves 218, 220 and 222, respectively, arranged in a commonplane or line with one another. Each of connector sleeves 218, 220, 222is configured to mate with respective first, second and third driveconnectors 118, 120, 122 of surgical device 100, as described above.Each of connector sleeves 218, 220, 222 is further configured to matewith a proximal end of respective first, second and third proximal driveshafts 212, 214, 216.

Inner housing assembly 210 also includes, as illustrated in FIGS. 6, 17,27 and 28, a first, a second and a third biasing member 224, 226 and 228disposed distally of respective first, second and third connectorsleeves 218, 220, 222. Each of biasing members 224, 226 and 228 isdisposed about respective first, second and third rotatable proximaldrive shaft 212, 214 and 216. Biasing members 224, 226 and 228 act onrespective connector sleeves 218, 220 and 222 to help maintain connectorsleeves 218, 220 and 222 engaged with the distal end of respective driverotatable drive connectors 118, 120, 122 of surgical device 100 whenadapter assembly 200 is connected to surgical device 100.

In particular, first, second and third biasing members 224, 226 and 228function to bias respective connector sleeves 218, 220 and 222 in aproximal direction. In this manner, during assembly of adapter assembly200 to surgical device 100, if first, second and or third connectorsleeves 218, 220 and/or 222 is/are misaligned with the drive connectors118, 120, 122 of surgical device 100, first, second and/or third biasingmember(s) 224, 226 and/or 228 are compressed. Thus, when surgical device100 is operated, drive connectors 118, 120, 122 of surgical device 100will rotate and first, second and/or third biasing member(s) 224, 226and/or 228 will cause respective first, second and/or third connectorsleeve(s) 218, 220 and/or 222 to slide back proximally, effectivelycoupling drive connectors 118, 120, 122 of surgical device 100 to first,second and/or third proximal drive shaft(s) 212, 214 and 216 of innerhousing assembly 210.

Adapter assembly 200 includes a plurality of force/rotationtransmitting/converting assemblies, each disposed within inner housingassembly 204 and outer tube 206. Each force/rotationtransmitting/converting assembly is configured and adapted totransmit/convert a speed/force of rotation (e.g., increase or decrease)of first, second and third rotatable drive connectors 118, 120 and 122of surgical instrument 100 before transmission of such rotationalspeed/force to loading unit 300.

Specifically, as illustrated in FIG. 6, adapter assembly 200 includes afirst, a second and a third force/rotation transmitting/convertingassembly 240, 250, 260, respectively, disposed within inner housing 208and outer tube 206. Each force/rotation transmitting/converting assembly240, 250, 260 is configured and adapted to transmit or convert arotation of a first, second and third drive connector 118, 120, 122 ofsurgical device 100 into axial translation of articulation bar 258 ofadapter assembly 200, to effectuate articulation of loading unit 300; arotation of a ring gear 266 of adapter assembly 200, to effectuaterotation of adapter assembly 200; or axial translation of a distal drivemember 248 of adapter assembly 200 to effectuate closing, opening andfiring of loading unit 300.

As shown in FIGS. 5, 6 and 24-31, first force/rotationtransmitting/converting assembly 240 includes first rotatable proximaldrive shaft 212, which, as described above, is rotatably supportedwithin inner housing assembly 204. First rotatable proximal drive shaft212 includes a non-circular or shaped proximal end portion configuredfor connection with first connector 218 which is connected to respectivefirst connector 118 of surgical device 100. First rotatable proximaldrive shaft 212 includes a distal end portion 212 b having a threadedouter profile or surface.

First force/rotation transmitting/converting assembly 240 furtherincludes a drive coupling nut 244 rotatably coupled to threaded distalend portion 212 b of first rotatable proximal drive shaft 212, and whichis slidably disposed within outer tube 206. Drive coupling nut 244 isslidably keyed within proximal core tube portion of outer tube 206 so asto be prevented from rotation as first rotatable proximal drive shaft212 is rotated. In this manner, as first rotatable proximal drive shaft212 is rotated, drive coupling nut 244 is translated along threadeddistal end portion 212 b of first rotatable proximal drive shaft 212and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 furtherincludes a distal drive member 248 that is mechanically engaged withdrive coupling nut 244, such that axial movement of drive coupling nut244 results in a corresponding amount of axial movement of distal drivemember 248. The distal end portion of distal drive member 248 supports aconnection member 247 configured and dimensioned for selectiveengagement with a drive member 374 of drive assembly 360 of loading unit300 (FIG. 48). Drive coupling nut 244 and/or distal drive member 248function as a force transmitting member to components of loading unit300, as described in greater detail below.

In operation, as first rotatable proximal drive shaft 212 is rotated,due to a rotation of first connector sleeve 218, as a result of therotation of the first respective drive connector 118 of surgical device100, drive coupling nut 244 is caused to be translated axially alongfirst distal drive shaft 242. As drive coupling nut 244 is caused to betranslated axially along first distal drive shaft 242, distal drivemember 248 is caused to be translated axially relative to outer tube206. As distal drive member 248 is translated axially, with connectionmember 247 connected thereto and engaged with drive member 374 of driveassembly 360 of loading unit 300 (FIG. 48), distal drive member 248causes concomitant axial translation of drive member 374 of loading unit300 to effectuate a closure of tool assembly 304 and a firing of toolassembly 304 of loading unit 300.

With reference to FIGS. 5-11, 19 and 23-31, second drive converterassembly 250 of adapter assembly 200 includes second proximal driveshaft 214 rotatably supported within inner housing assembly 204. Secondrotatable proximal drive shaft 214 includes a non-circular or shapedproximal end portion configured for connection with second connector orcoupler 220 which is connected to respective second connector 120 ofsurgical device 100. Second rotatable proximal drive shaft 214 furtherincludes a distal end portion 214 b having a threaded outer profile orsurface.

Distal end portion 214 b of proximal drive shaft 214 is threadablyengaged with an articulation bearing housing 252 a of an articulationbearing assembly 252. Articulation bearing assembly 252 includes ahousing 252 a supporting an articulation bearing 253 having an innerrace 253 b that is independently rotatable relative to an outer race 253a. Articulation bearing housing 252 a has a non-circular outer profile,for example tear-dropped shaped, that is slidably and non-rotatablydisposed within a complementary bore 204 c (FIGS. 25, 26, 29 and 33) ofinner housing hub 204 a.

Second drive converter assembly 250 of adapter assembly 200 furtherincludes an articulation bar 258 having a proximal portion 258 a securedto inner race 253 b of articulation bearing 253. A distal portion 258 bof articulation bar 258 includes a slot 258 c therein, which isconfigured to accept a portion 366, e.g., a flag, articulation link(FIG. 48) of loading unit 300. Articulation bar 258 functions as a forcetransmitting member to components of loading unit 300, as described ingreater detail below.

With further regard to articulation bearing assembly 252, articulationbearing assembly 252 is both rotatable and longitudinally translatable.Additionally, it is envisioned that articulation bearing assembly 252allows for free, unimpeded rotational movement of loading unit 300 whenits jaw members 306, 308 are in an approximated position and/or when jawmembers 306, 308 are articulated (FIG. 48).

In operation, as second proximal drive shaft 214 is rotated due to arotation of second connector sleeve 220, as a result of the rotation ofthe second drive connector 120 of surgical device 100, articulationbearing assembly 252 is caused to be translated axially along threadeddistal end portion 214 b of second proximal drive shaft 214, which inturn causes articulation bar 258 to be axially translated relative toouter tube 206. As articulation bar 258 is translated axially,articulation bar 258, being coupled to articulation link 366 of loadingunit 300, causes concomitant axial translation of articulation link 366of loading unit 300 to effectuate an articulation of tool assembly 304(FIG. 48). Articulation bar 258 is secured to inner race 253 b ofarticulation bearing 253 and is thus free to rotate about thelongitudinal axis X-X relative to outer race 253 a of articulationbearing 253.

As illustrated in FIGS. 6, 17, 18, 20-23, 25-28, 31 and 37-40 and asmentioned above, adapter assembly 200 includes a third force/rotationtransmitting/converting assembly 260 supported in inner housing assembly204. Third force/rotation transmitting/converting assembly 260 includesa rotation ring gear 266 fixedly supported in and connected to outerknob housing 202. Ring gear 266 defines an internal array of gear teeth266 a (FIG. 6). Ring gear 266 includes a pair of diametrically opposed,radially extending protrusions 266 b (FIG. 6) projecting from an outeredge thereof. Protrusions 266 b are disposed within recesses defined inouter knob housing 202, such that rotation of ring gear 266 results inrotation of outer knob housing 202, and vice a versa.

Third force/rotation transmitting/converting assembly 260 furtherincludes third rotatable proximal drive shaft 216 which, as describedabove, is rotatably supported within inner housing assembly 204. Thirdrotatable proximal drive shaft 216 includes a non-circular or shapedproximal end portion configured for connection with third connector 222which is connected to respective third connector 122 of surgical device100. Third rotatable proximal drive shaft 216 includes a spur gear 216 akeyed to a distal end thereof. A reversing spur gear 264 inter-engagesspur gear 216 a of third rotatable proximal drive shaft 216 to gearteeth 266 a of ring gear 266.

In operation, as third rotatable proximal drive shaft 216 is rotated,due to a rotation of third connector sleeve 222, as a result of therotation of the third drive connector 122 of surgical device 100, spurgear 216 a of third rotatable proximal drive shaft 216 engages reversinggear 264 causing reversing gear 264 to rotate. As reversing gear 264rotates, ring gear 266 also rotates thereby causing outer knob housing202 to rotate. As outer knob housing 202 is rotated, outer tube 206 iscaused to be rotated about longitudinal axis “X” of adapter assembly200. As outer tube 206 is rotated, loading unit 300, that is connectedto a distal end portion of adapter assembly 200, is also caused to berotated about a longitudinal axis of adapter assembly 200.

Adapter assembly 200 further includes, as seen in FIGS. 1B, 3-5, 16, 17,20 and 24-26, an attachment/detachment button 272 supported thereon.Specifically, button 272 is supported on drive coupling assembly 210 ofadapter assembly 200 and is biased by a biasing member 274 to anun-actuated condition. Button 272 includes lip or ledge 272 a formedtherewith that is configured to snap behind a corresponding lip or ledge108 b defined along recess 108 a of connecting portion 108 of surgicaldevice 100. In use, when adapter assembly 200 is connected to surgicaldevice 100, lip 272 a of button 272 is disposed behind lip 108 b ofconnecting portion 108 of surgical device 100 to secure and retainadapter assembly 200 and surgical device 100 with one another. In orderto permit disconnection of adapter assembly 200 and surgical device 100from one another, button 272 is depresses or actuated, against the biasof biasing member 274, to disengage lip 272 a of button 272 and lip 108b of connecting portion 108 of surgical device 100.

With reference to FIGS. 1A, 2A, 2B, 3-5 and 24-26, adapter assembly 200further includes a lock mechanism 280 for fixing the axial position andradial orientation of distal drive member 248. Lock mechanism 280includes a button 282 slidably supported on outer knob housing 202. Lockbutton 282 is connected to an actuation bar 284 that extendslongitudinally through outer tube 206. Actuation bar 284 moves upon amovement of lock button 282. Upon a predetermined amount of movement oflock button 282, a distal end of actuation bar 284 may move into contactwith a lock out (not shown), which causes the lock out to cam a cammingmember 288 (FIG. 24) from a recess 249 in distal drive member 248. Whencamming member 288 is in engagement with recess 249 (e.g., at leastpartially within recess 249, see FIGS. 6 and 24), the engagement betweencamming member 288 and distal drive member 248 effectively locks theaxial and rotational position of end effector 300 that is engaged withconnection member 247.

In operation, in order to lock the position and/or orientation of distaldrive member 248, a user moves lock button 282 from a distal position toa proximal position (FIGS. 25 and 26), thereby causing the lock out (notshown) to move proximally such that a distal face of the lock out movesout of contact with camming member 288, which causes camming member 288to cam into recess 249 of distal drive member 248. In this manner,distal drive member 248 is prevented from distal and/or proximalmovement. When lock button 282 is moved from the proximal position tothe distal position, the distal end of actuation bar 284 moves distallyinto the lock out, against the bias of a biasing member (not shown), toforce camming member 288 out of recess 249, thereby allowing unimpededaxial translation and radial movement of distal drive member 248.

Reference may be made to U.S. Pat. No. 9,597,104, the entire content ofwhich is incorporated herein by reference, for a more detaileddiscussion of the construction and operation of lock mechanism 280.

With reference to FIGS. 1B, 6, 12A-15 and 25-28, adapter assembly 200includes an electrical assembly 290 supported on and in outer knobhousing 202 and inner housing assembly 204. Electrical assembly 290includes an electrical connector 292 supported on a circuit board 294,for electrical connection to a corresponding electrical plug 190disposed in connecting portion 108 of surgical device 100.

With particular reference to FIGS. 12A-12D, electrical connector 292includes a plurality of electrical contact pins 293 and a housing orconnector housing 295. Electrical contact pins 293 serve to allow forcalibration and communication of life-cycle information to the circuitboard of surgical device 100 via electrical plugs 190 that areelectrically connected to the circuit board (not shown) of surgicaldevice 100.

Each electrical contact pin 293 includes a distal portion 293 a and aproximal portion 293 b. Distal portion 293 a of each contact pin 293 isconfigured to engage circuit board 294, e.g., via soldering. Proximalportion 293 b of each contact pin 293 is configured to releasably engagecorresponding electrical plug 190 disposed in connecting portion 108 ofsurgical device 100. With continued reference to FIGS. 12A-12D, distalportion 293 a of each electrical contact pin 293 is tapered tofacilitate insertion into holes 294 a (FIG. 12B) of circuit board 294.Proximal portion 293 b of each electrical contact pin 293 includes arectangular cross-section, and is tapered and chamfered to facilitateengagement and disengagement with electrical plug 190.

Additionally, each electrical contact pin 293 includes a hole 293 cextending laterally therethrough. Hole 293 c is configured to facilitatethe connection between electrical contact pins 293 and housing 295. Itis envisioned that housing 295 is over-molded, such that portions of theover-mold extend through holes 293 c in electrical contact pins 293. Ascan be appreciated, the engagement between electrical contact pins 293and housing 295 helps maintain proper alignment of pins 293 to furtherfacilitate engagement between electrical connector 292 and circuit board294 and electrical plug 190, and to further facilitate engagementbetween electrical connector 292 and electrical plug 190. While sevenelectrical contact pins 293 are shown, it is envisioned that more orfewer electrical contact pins 293 are included with electrical assembly290.

With continued reference to FIGS. 12A-12D, housing 295 of electricalconnector 292 includes a rectangular cross-section. The rectangularcross-section of housing 295 is configured to mate with a rectangularopening of proximal cap 210 a (FIGS. 5 and 6) of drive coupling assembly210 to prevent radial movement therebetween.

Housing 295 also includes a plurality of projections 297 extendingtherefrom. Projections 297 each include a distal face 297 a and aproximal face 297 b. Distal face 297 a of each projection 297 isconfigured and positioned to contact circuit board 294 during insertionof electrical connector 292. Thus, distal face 297 a of each projection297 prevents electrical contact pins 293 of electrical connector 292from being inserted too far distally into holes 294 a of circuit board294. While distal face 297 a of each projection 297 is illustrated asbeing flush with a distal face 295 a of housing 295 (FIG. 12D), it isenvisioned that distal face 297 a of each projection 297 is positionedfarther proximally or distally than distal face 295 a of housing 295.Proximal face 297 b of each projection 297 is configured and positionedto prevent disengagement between electrical connector 292 and circuitboard 294, e.g., during disengagement between surgical device 100 andadapter assembly 200. More particularly, a surface of proximal cap 210of electrical assembly 290 is configured to abut proximal face 297 b ofat least one or all projections 297, thus preventing proximal movementof electrical connector 292 with respect to circuit board 294. In theillustrated embodiment, two projections 297 extend from a first surface295 b of housing 295, and two projections 297 extend from a secondsurface 295 c of housing 295. However, housing 295 may include more orfewer projections 297.

Electrical assembly 290 further includes a strain gauge 296 electricallyconnected to circuit board 294. Strain gauge 296 is provided with anotch 296 a which is configured and adapted to receive stem 204 d of hub204 a of inner housing assembly 204. Stem 204 d of hub 204 a functionsto restrict rotational movement of strain gauge 296. As illustrated inFIGS. 25-28, first rotatable proximal drive shaft 212 extends throughstrain gauge 296. Strain gauge 296 provides a closed-loop feedback to afiring/clamping load exhibited by first rotatable proximal drive shaft212.

Electrical assembly 290 also includes a slip ring 298 disposed withinouter tube 206. Slip ring 298 is in electrical connection with circuitboard 294. Slip ring 298 functions to permit rotation of first rotatableproximal drive shaft 212 and axial translation of drive coupling nut 244while still maintaining electrical contact of electrical contact rings298 a thereof with at least another electrical component within adapterassembly 200, and while permitting the other electrical components torotate about first rotatable proximal drive shaft 212 and drive couplingnut 244

Electrical assembly 290 may include a slip ring cannula or sleeve 299positioned core tube of tube 206 to protect and/or shield any wiresextending from slip ring 298.

Turning now to FIGS. 6, 11, 14, 32 and 33, inner housing assembly 204has been designed to reduce incidents of racking of second proximaldrive shaft 214 as drive shaft 214 rotates to axially translatearticulation bearing assembly 252. Inner housing assembly 204 includes ahub 204 a having a distally oriented annular wall 204 b defining asubstantially circular outer profile, and defining a substantiallytear-drop shaped inner recess or bore 204 c. Bore 204 c of hub 204 a isshaped and dimensioned to slidably receive articulation bearing assembly252 therewithin.

Inner housing assembly 204 includes a ring plate 254 a (FIG. 34) securedto a distal face of distally oriented annular wall 204 b of hub 204 a.Plate 254 a defines an aperture 254 e therethrough that is sized andformed therein so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip 214 c of second proximal driveshaft 214. In this manner, distal tip 214 c of second proximal driveshaft 214 is supported and prevented from moving radially away from alongitudinal rotational axis of second proximal drive shaft 214 assecond proximal drive shaft 214 is rotated to axially translatearticulation bearing assembly 252.

As illustrated in FIGS. 14, 32, 39 and 40, hub 204 a defines a feature(e.g., a stem or the like) 204 d projecting therefrom which functions toengage notch 296 a of strain gauge 296 of electrical assembly 290 tomeasure forces experienced by shaft 212 as surgical device 100 isoperated.

With reference to FIGS. 35-40, a plate bushing 230 of inner housingassembly 204 is shown and described. Plate bushing 230 extends acrosshub 204 a of inner housing assembly 204 and is secured to hub 204 a byfastening members. Plate bushing 230 defines three apertures 230 a, 230b, 230 c that are aligned with and rotatably receive respective first,second and third proximal drive shafts 212, 214, 216 therein. Platebushing 230 provides a surface against which first, second and thirdbiasing members 224, 226 and 228 come into contact or rest against.

While plate bushing 230 has been shown and described as being a unitarymonolithic piece, as illustrated in FIGS. 6 and 37-40, it is envisionedand within the scope of the present application that plate bushing 230may be separated into several parts including, and not limited to, asseen in FIGS. 40-42, a support plate 230′ extending across drive shafts212, 214, 216, and a separate bushing for each of drive shafts 212, 214,216 and disposed between the support plate 230′ and hub 204 a of innerhousing assembly 204. Support plate 230′ may include a pair of slots 230a′, 230 b′ formed therein, which are configured and adapted to receivetabs 296 b of strain gauge 296 that project axially therefrom.

Turning now to FIGS. 43-47, an inner housing assembly 204′ according toanother embodiment of the present disclosure is shown and will bedescribed. In order to reduce incidents of racking (i.e., distal end 214b of second proximal drive shaft 214 moving radially away from alongitudinal rotational axis thereof) of second proximal drive shaft 214as drive shaft 214 rotates to axially translate articulation bearingassembly 252, inner housing assembly 204′ may include a reinforcementframe or bracket assembly 254′. Bracket assembly 254′ includes a firstplate 254 a′ and a second plate 254 b′ integrally connected to andspaced a distance from first plate 254 a′ by a plurality of connectingrods 254 c′ extending therebetween.

First plate 254 a′ is disposed adjacent to or in close proximity to ringgear 266 and defines an aperture 254 d′ therethrough. Aperture 254 d′ issized and formed in first plate 254 a′ so as to be aligned with secondproximal drive shaft 214 and to permit second proximal drive shaft 214to freely rotate therewithin. Second plate 254 b′ is spaced from firstplate 254 a′ so as to be disposed at a distal free end of secondproximal drive shaft 214. Second plate 254 b′ defines an aperture 254 e′therethrough. Aperture 254 e′ is sized and formed in second plate orflange 254 b′ so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip 214 c of second proximal driveshaft 214.

In this manner, distal tip 214 c of second proximal drive shaft 214 issupported and prevented from moving radially away from a longitudinalrotational axis of second proximal drive shaft 214 as second proximaldrive shaft 214 is rotated to axially translate articulation bearingassembly 252.

As illustrated in FIGS. 38, 46 and 47, inner housing assembly 204′ mayinclude a reinforcing sleeve 255′ disposed about bracket assembly 254′to further reinforce bracket assembly 254′. It is contemplated in anembodiment that reinforcing sleeve 255′ may be interposed between firstplate 254 a′ and second plate 254 b′ of bracket assembly 254′. It isfurther contemplated that reinforcing sleeve 255′ may be interposedbetween second plate 254 b′ and a distally oriented face of proximalinner housing assembly 204′.

In accordance with the present disclosure, an overall length of adapterassembly 200 has been reduced as compared to prior adapter assembliesthat have been developed to transmit/convert forces/rotations fromsurgical device 100 to loading unit 300. By reducing an overall lengthof adapter assembly 200, a center of gravity of an assembled surgicaldevice 100, adapter assembly 200 and loading unit 300 has been shiftedproximally as compared to a center of gravity of an assembled surgicaldevice 100, a prior adapter assembly and a loading unit 300. As such, alevel of comfort to the end user in using the electromechanical surgicalsystem of the present disclosure has been increased, and a level offatigue has been decreased.

In operation, when a button of surgical device 100 is activated by theuser, the software checks predefined conditions. If conditions are met,the software controls the motors and delivers mechanical drive to theattached surgical stapler, which can then open, close, rotate,articulate or fire depending on the function of the pressed button. Thesoftware also provides feedback to the user by turning colored lights onor off in a defined manner to indicate the status of surgical device100, adapter assembly 200 and/or loading unit 300.

Reference may be made to U.S. Pat. No. 7,819,896, entitled “TOOLASSEMBLY FOR A SURGICAL STAPLING DEVICE” for a detailed discussion ofthe construction and operation of loading unit 300, as illustrated inFIGS. 1 and 48.

Any of the components described herein may be fabricated from eithermetals, plastics, resins, composites or the like taking intoconsideration strength, durability, wearability, weight, resistance tocorrosion, ease of manufacturing, cost of manufacturing, and the like.

It will be understood that various modifications may be made to theembodiments of the presently disclosed adapter assemblies. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

What is claimed is:
 1. A surgical instrument comprising: a drive shaftincluding a proximal portion and a distal portion, the proximal portionof the drive shaft defining a longitudinal axis, the drive shaft beingrotatable about the longitudinal axis; a bearing assembly disposed inmechanical cooperation with the drive shaft such that rotation of thedrive shaft about the longitudinal axis longitudinally translates thebearing assembly relative to the drive shaft; and a housing assemblyconfigured to limit the distal portion of the drive shaft from movingaway from the longitudinal axis, the housing assembly including: a firstplate defining a first aperture therethrough, a portion of the driveshaft extending through the first aperture; a second plate positioneddistally of the first plate and defining a second aperture therethrough,a portion of the drive shaft extending through the second aperture; andat least one rod interconnecting the first plate and the second plate.2. The surgical instrument according to claim 1, wherein the firstaperture and the second aperture are radially aligned.
 3. The surgicalinstrument according to claim 1, wherein the first plate is positionedproximally of the bearing assembly.
 4. The surgical instrument accordingto claim 1, wherein the second plate is positioned distally of thebearing assembly.
 5. The surgical instrument according to claim 1,wherein the bearing assembly is positioned distally of the first plateand proximally of the second plate.
 6. The surgical instrument accordingto claim 1, wherein the at least one rod includes at least three rods.7. The surgical instrument according to claim 1, wherein the drive shaftis rotatable within the first aperture relative to the first plate. 8.The surgical instrument according to claim 1, wherein the drive shaft isrotatable within the second aperture relative to the second plate. 9.The surgical instrument according to claim 1, wherein the secondaperture rotationally supports a distal tip of the drive shaft.
 10. Thesurgical instrument according to claim 1, wherein the first aperture islarger than the second aperture.
 11. The surgical instrument accordingto claim 1, further comprising a cylindrical sleeve extending betweenfirst plate and second plate.
 12. The surgical instrument according toclaim 11, wherein the cylindrical sleeve is disposed radially outward ofthe at least one rod.
 13. A surgical instrument comprising: a driveshaft including a proximal portion and a distal portion, the proximalportion of the drive shaft defining a longitudinal axis, the drive shaftbeing rotatable about the longitudinal axis; and a housing assemblyconfigured to limit the distal portion of the drive shaft from movingaway from the longitudinal axis, the housing assembly including: a firstplate defining a first aperture therethrough, a portion of the driveshaft extending through the first aperture; a second plate positioneddistally of the first plate and defining a second aperture therethrough,a portion of the drive shaft extending through the second aperture; andat least one rod interconnecting the first plate and the second plate.14. The surgical instrument according to claim 13, wherein the firstaperture and the second aperture are radially aligned.
 15. The surgicalinstrument according to claim 13, wherein the at least one rod includesat least three rods.
 16. The surgical instrument according to claim 13,wherein the drive shaft is rotatable within the first aperture relativeto the first plate.
 17. The surgical instrument according to claim 13,wherein the drive shaft is rotatable within the second aperture relativeto the second plate.
 18. The surgical instrument according to claim 13,wherein the second aperture rotationally supports a distal tip of thedrive shaft.
 19. The surgical instrument according to claim 13, whereinthe first aperture is larger than the second aperture.
 20. The surgicalinstrument according to claim 13, further comprising a cylindricalsleeve extending between first plate and second plate.